Tooling and method for manufacturing a fiber optic array

ABSTRACT

A fixture is for forming a fiber optic array that defines a plurality of discrete fibers extending from a spaced-apart arrangement to a consolidated arrangement wherein the fibers are layered next to each other for a further ribbonizing process. The fixture includes a pair of contact blades that are configured to slide along a direction transverse to the longitudinal axes of the fibers for consolidating the fibers.

CROSS-REFERENCE TO RELATED APPLICATION

The present application is a continuation of U.S. patent applicationSer. No. 17/344,240, filed Jun. 10, 2021; which is a continuation ofU.S. patent application Ser. No. 15/822,613, filed Nov. 27, 2017, nowU.S. Pat. No. 11,036,023; which is a continuation of U.S. patentapplication Ser. No. 14/816,254, filed Aug. 3, 2015, now U.S. Pat. No.9,829,667; which claims the benefit of U.S. Provisional PatentApplication Ser. No. 62/033,287, filed Aug. 5, 2014, which applicationsare hereby incorporated by reference in their entireties.

BACKGROUND OF THE INVENTION

As demand for telecommunications increases, fiber optic networks arebeing extended in more and more areas. Management of the cables, ease ofinstallation, and case of accessibility for later management areimportant concerns. As a result, there is a need for fiber optic deviceswhich address these and other concerns.

SUMMARY

An aspect of the present disclosure relates to tooling and methods formanufacturing a fiber optic array that may be housed in further opticaldistribution equipment. According to certain embodiments, such opticaldistribution equipment may include fiber optic cassettes configured forrelaying a fiber optic signal from a signal input location to a signaloutput location or a plurality of signal output locations. According toone specific example, such a fiber optic cassette may comprise a bodydefining a front and an opposite rear. A cable entry location may bedefined on the body (e.g., the rear) for a multi-fiber cable to enterthe cassette, and a cable exit location may be defined on the body(e.g., the front) for a plurality of fibers from the multi-fiber cableto exit the cassette. The multi-fiber cable may form at least a part ofthe fiber optic array to be housed within the fiber optic cassette.According to one example embodiment, a plurality of optical fibers fromthe cable are to extend into the cassette and form terminations adjacentthe front of the body as part of the fiber optic array. The fiber opticarray of the present disclosure may include a substrate that is to bepositioned between the cable entry location and the terminationsadjacent the front of the body of the cassette, wherein the substraterigidly supports the plurality of optical fibers. Each of theterminations adjacent the front of the body of the cassette may includea ferrule and a ferrule hub supporting the ferrule. The terminations ofthe fiber optic array may be positioned at the front of the body of thecassette in structures such as fiber optic adapters for furtherconnectivity to signal carrying outside fiber optic connectors.

According to the present disclosure, another aspect relates to a fiberoptic array comprising a plurality of optical fibers, a substrate forsupporting the plurality of optical fibers, the substrate defining afirst end and a second end, and a plurality of spaced-apart channelsdefining parallel portions at the first end of the substrate and a fiberclamp provided at the second end of the substrate. The plurality ofoptical fibers are positioned on the substrate such that the fibersextend from being spaced-apart via the channels to a consolidatedarrangement wherein the fibers are layered next to each other. The fiberclamp secures the consolidated fibers at the second end of thesubstrate.

According to another aspect, the present disclosure is directed to afixture for forming a fiber optic array that defines a plurality ofdiscrete fibers extending from a spaced-apart arrangement to aconsolidated arrangement wherein the fibers are layered next to eachother for a further ribbonizing process. The fixture comprises a pair ofcontact blades that are configured to slide along a direction transverseto the longitudinal axes of the fibers for consolidating the fibers.

According to another aspect, the present disclosure is directed to amethod for forming a fiber optic array that defines a plurality ofdiscrete fibers extending from a spaced-apart arrangement to aconsolidated arrangement wherein the fibers are layered next to eachother for a further ribbonizing process, the method comprising layingthe fibers within spaced-apart channels defined on a fixture, thechannels having parallel portions; moving a pair of contact blades onthe fixture along a direction transverse to the longitudinal axes of thefibers to abut and to consolidate the fibers; and securing together thefibers at both the spaced-apart portion of the array and theconsolidated portion of the array. According to one example embodiment,the channels are defined by a substrate that is provided as a removableinsert of the fixture.

According to another example embodiment, the method further comprisessecuring the formed fiber optic array between two polymeric sheets toform a flexible optical circuit.

A variety of additional inventive aspects will be set forth in thedescription that follows. The inventive aspects can relate to individualfeatures and combinations of features. It is to be understood that boththe foregoing general description and the following detailed descriptionare exemplary and explanatory only and are not restrictive of the broadinventive concepts upon which the embodiments disclosed herein arebased.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates an example embodiment of an inventive fiber opticarray formed according to the inventive methods and tooling of thepresent disclosure;

FIGS. 2-9A illustrate an example inventive method and tooling forforming the fiber optic array illustrated in FIG. 1;

FIGS. 10-22 illustrate an example inventive method and tooling forforming a fiber optic array similar to that shown in FIG. 1, except thatthe array formed by the method illustrated in FIGS. 10-22 includescrossed-over fiber pairs;

FIG. 23 illustrates the inventive fiber optic array formed according tothe method and tooling illustrated in FIGS. 10-22;

FIGS. 24-31 illustrate an example method and tooling for forming a fiberoptic array similar to that shown in FIGS. 1 and 23, except that thearray formed by the method illustrated in FIGS. 24-31 is an example of apreform that can be further processed into a flexible optical circuit;and

FIG. 32 shows a flexible optical circuit formed from the arraymanufactured by the inventive method and tooling illustrated in FIGS.24-31.

DETAILED DESCRIPTION

The present disclosure is directed generally to tooling and methods formanufacturing a fiber optic array 10 that may be housed in opticaldistribution equipment such as fiber optic cassettes.

According to certain embodiments, such fiber optic cassettes may beconfigured for relaying a fiber optic signal from a signal inputlocation to a signal output location or a plurality of signal outputlocations. According to one specific example, such a fiber opticcassette may comprise a body defining a front and an opposite rear. Acable entry location may be defined on the body (e.g., the rear) for amulti-fiber cable to enter the cassette, and a cable exit location maybe defined on the body (e.g., the front) for a plurality of fibers fromthe multi-fiber cable to exit the cassette.

The multi-fiber cable may form at least a part of the fiber optic array10 to be housed within the fiber optic cassette. According to oneexample embodiment, a plurality of optical fibers 12 from the cable areto extend into the cassette and form terminations 14 adjacent the frontof the body as part of the fiber optic array 10. As will be discussed infurther detail below, the fiber optic array 10 of the present disclosuremay further include a substrate 16 that is to be positioned between thecable entry location and the terminations 14 adjacent the front of thebody of the cassette, wherein the substrate 16 rigidly supports theplurality of optical fibers 12.

Each of the terminations 14 defined by the array that become positionedadjacent the front of the body of the cassette may include a ferrule 18and a ferrule hub 20 supporting the ferrule 18. The terminations 14 ofthe fiber optic array 10 may be positioned at the front of the body ofthe cassette in structures such as fiber optic adapters for furtherconnectivity to signal carrying outside fiber optic connectors.

As noted above, the fiber optic cassettes that are configured to housethe fiber optic arrays 10 formed via the tooling and the methods of thepresent disclosure are designed to relay multiple fibers 12 whichterminate at a rear connector, such as an MPO style connector, to aplurality of ferrules 18 positioned at a generally front portion of thecassette. Such fiber optic cassettes, thus, provide a transition housingor support between multi-fibered connectors, such as the MPO styleconnectors having MT ferrules, and single or dual fiber connectors, suchas LC or SC type connectors.

Examples of fiber optic cassettes that may house fiber optic arrays 10formed in accordance with the present disclosure are disclosed andfurther described in International Publication Nos. WO 2014/052441 andWO 2014/052446, the entire disclosures of which are incorporated hereinby reference.

As will be described in further detail below, some of the embodiments ofthe fiber optic arrays manufactured according to the present disclosuremay form parts of flexible optical circuits. According to one exampleembodiment, the fiber optic arrays manufactured according to the presentdisclosure may be arrays that are provided as preforms that can beformed into flexible optical circuits with further processing.

Flexible optic circuits are configured for transitioning betweenmulti-fibered connectors positioned at one end of a piece of fiber opticequipment such as a cassette and single or dual connectors positioned atan opposite end of the cassette. Flexible optical circuits are passiveoptical components that comprise one or more (typically, multiple)optical fibers imbedded on a flexible sheet or substrate, such as aMylar™ or other flexible polymer material. Commonly, although notnecessarily, one end face of each fiber is disposed adjacent onelongitudinal end of the flexible optical circuit substrate, and theother end face of each fiber is disposed adjacent the oppositelongitudinal end of the flexible optical circuit substrate. The fibersextend past the longitudinal ends of the flexible optical circuit(commonly referred to as pigtails) so that they can be terminated tooptical ferrules or optical connectors, which can be coupled to fiberoptic cables or other fiber optic components through mating opticalconnectors.

Flexible optical circuits essentially comprise one or more fiberssandwiched between two flexible sheets of material, such as Mylar™ oranother polymer. An epoxy may be included between the two sheets inorder to adhere them together. Alternately, depending on the sheetmaterial and other factors, the two sheets may be heated above theirmelting point to heat-weld them together with the fibers embeddedbetween the two sheets.

Examples of fiber optic cassettes that house flexible optical circuits,at least portions of which are formed according to the presentdisclosure are described in further detail in International PublicationNos. WO 2014/052441 and WO 2014/052446, the entire disclosures of whichhave been incorporated herein by reference.

Now referring to FIG. 1, an example of a fiber optic array 10 that hasbeen manufactured via the tooling and the methods of the presentdisclosure is illustrated.

As seen in the example depicted in FIG. 1, the fiber optic array 10includes the support substrate 16 (may also be referred to as an insertwith respect to the tooling described in the present disclosure). Thesupport substrate 16 defines a front end 22 and a rear end 24. The frontend 22 defines a plurality of channels 26 for supporting fiber pigtails12. The depicted example of the fiber optic array 10 shows the fiberpigtails 12 as having been terminated to fiber optic ferrules 18 thatare supported by ferrule hubs 20. It should be noted that the ferrules18 terminated to the ends of the fibers 12 that extend from the frontend 22 of the substrate 16 may become parts of conventional ornon-conventional fiber optic connectors. It should be noted that theterm “non-conventional connector” may refer to a fiber optic connectorthat is not of a conventional type such as an LC or SC connector and onethat has generally not become a recognizable standard footprint forfiber optic connectivity in the industry. Such conventional ornon-conventional connectors may relay the signals to further connectorsvia structures such as fiber optic adapters that may be formed as partof the cassettes that house the arrays 10 of the present disclosure.

In the depicted embodiment of the fiber optic array 10, the channels 26at the front end 22 of the substrate 16 are sized to frictionallyreceive and secure the buffer tube portions of the optical fibers 12.Termination of the fibers 12 extending from the front end 22 of thesubstrate 16 to form the pigtails may include securing of the buffertubes to the ferrule hubs 20. Examples of methods for terminating anoptical fiber to a fiber optic ferrule is described and illustrated inInternational Publication Nos. WO 2014/052441 and WO 2014/052446, theentire disclosures of which have been incorporated herein by reference.

It should be noted that the methods described in InternationalPublication Nos. WO 2014/052441 and WO 2014/052446 relate to thetermination of optical fibers that are part of flexible opticalcircuits. However, similar principals may be used for terminating fibers12 that are not part of a flexible optical circuit in forming thepigtails depicted in FIG. 1.

Still referring to FIG. 1, the channels 26 at the front end 22 of thesubstrate 16 are configured to transition the fibers 12 to a fiberconsolidation point 28 at the rear end 24 of the substrate 16. Thechannels 26 define curved rear portions 40. The curvature of thechannels 26 are designed to protect the minimum bend radius requirementsof the fibers 12 as the fibers 12 extend from the front end 22 to therear end 24 of the substrate 16.

At the fiber consolidation point 28 at the rear end 24 of the substrate16, the fiber optic array 10 defines a fiber clamp 30 for clamping theconsolidated fibers 12. The fiber clamp 30 is formed via a clip 32 thatsnap-fits into openings 34 defined at the rear end 24 of the substrate16, as shown in FIG. 2. The fiber clamp 30 is configured to keep theconsolidated fibers 12 in a given arrangement for further processing(e.g., ribbonizing). In certain embodiments, the clip 32 may include afoam adhesive pad 33 underside the clip 32 to help restrain the fibers12 and to keep them in the consolidated arrangement (see FIG. 9A). Inthe array 10 and clamp 30 depicted in FIG. 1, the fibers 12 at the rearend 24 of the substrate 16 are horizontally layered for ribbonizing andtermination to a multi-fiber ferrule of a multi-fiber connector such asan MPO style connector. As noted previously, such an MPO connector mayform the signal input location of the fiber optic cassette that housesthe fiber optic array 10 of the present disclosure.

Still referring to FIG. 1, the fiber optic array 10 includes a firstpiece of adhesive tape 36 used for securing the fibers 12 to thesubstrate 16 at the front end 22 of the substrate 16 and a second pieceof adhesive tape 38 for securing the fibers 12 at the curved portions 40of the channels 26 from which the fibers 12 extend toward theconsolidation point 28.

Now referring to FIGS. 2-9, examples of tooling and methods formanufacturing the fiber optic array 10 illustrated in FIG. 1 are hereindescribed.

In FIG. 2, a base 42 of a fixture 44 used in forming the fiber opticarray 10 is shown. The base 42 defines a front end 46, a rear end 48,and a bearing surface 50 extending therebetween against which the fibers12 can be laid. Adjacent the front end 46 of the base 42 is an insertcavity 52. The insert cavity 52 is configured to receive the substrate16 that eventually forms a part of the fiber optic array 10 as discussedabove. The substrate 16, thus, in such an embodiment is provided as aremovable insert of the fixture 44.

In other embodiments, as will be discussed in further detail below, thefiber array that is formed may lack a rigid substrate to support thefibers 12, and the channels that receive the fibers 12 may be anintegral part of the fixture rather than being provided on a removablestructure. Please see the fiber array 210 of FIGS. 24-32.

Referring back to FIG. 2, the fixture 44 includes a pair of contactblades 54 slidably attached to the base 42. The blades 54 are configuredto move along a direction transverse to the longitudinal axes of thefibers 12 that are positioned within the channels 26 and consolidate thefibers 12 to form the array 10 as shown in FIG. 1.

FIG. 3 shows the substrate insert 16 having been placed in the insertcavity 52, ready to receive the pigtails 12. FIGS. 4-5 show the fiberpigtails 12 loaded on the substrate insert 16.

As shown in FIG. 6, the fixture 44 includes clamping structures forkeeping the fibers 12 within the channels 26 before consolidation by thecontact blades 54. In FIG. 6, the fixture 44 is shown with a first clamp56 that is mounted adjacent the front end 46 of the base 42 for keepingthe fibers 12 within the channels 26. A second clamp 58 is providedadjacent the rear end 48 of the base 42 for keeping the fibers 12against the bearing surface 50. A guide clamp 60 is positioned betweenthe first and second clamps 56, 58. The guide clamp 60 keeps the fibers12 within the channels 26 of the substrate/insert 16 as the fibers 12transition from the parallel portions of the channels 26 to curved rearportions 40. As noted above, the curvature of the channels 26 aredesigned to protect the minimum bend radius requirements of the fibers12 as the fibers 12 transition from a spaced-apart arrangement to theconsolidation point 28 defined on the substrate 16, wherein the fibers12 become layered next to each other, ready for a further ribbonizingprocess.

The guide clamp 60 is also positioned such that a first space 62 isprovided between the first clamp 56 and the guide clamp 60. The firstspace 62 indicates the location for securing the first piece of adhesivetape 36 to the fibers 12. As noted above, the first piece of tape 36 isused for securing the fibers 12 to the substrate 16 at the front end 22of the substrate 16. As shown in FIG. 6, an opening 64 is also providedon the guide clamp 60. The opening 64 defines a second space 66 thatindicates the location for securing the second piece of adhesive tape 38to the fibers 12. The second piece of tape 38 is used for securing thefibers 12 at the curved portions 40 of the channels 26.

Referring now to FIG. 7, once the clamps 56, 58, 60 are all in place,the contact blades 54 are slidably moved along a direction transverse tothe longitudinal axes of the fibers 12 that are positioned within thechannels 26 and the fibers 12 are consolidated. Thus, using the contactblades 54, the fibers 12 are moved from a spaced-apart arrangement to aconsolidated arrangement wherein the fibers 12 end up layered next toeach other, ready for a ribbonizing process.

Referring to FIG. 8, once the fibers 12 have been consolidated, thefiber clamp 30 is applied at the consolidation point 28 defined by thesubstrate 16. In addition, the first and the second pieces of adhesivetape 36, 38 are applied at the first and second spaces 62, 66,respectively, to secure the fibers 12 to the substrate 16.

Referring to FIG. 9, the clamps 56, 58, 60 are removed from the base 42and the contact blades 54 are slidably moved away from each other.

When the substrate 16 is removed from the fixture 44, the fiber opticarray 10 that is shown in FIG. 1 has been formed.

Now referring to FIGS. 10-22, an example inventive method and toolingfor forming a fiber optic array 110 that is similar to that shown inFIG. 1 is illustrated. However, as will be described in further detail,the fiber optic array 110 formed according to the method and tooling ofFIGS. 10-22 includes crossed-over fiber pairs 112. FIG. 23 illustratesthe inventive fiber optic array 110 formed according to the method andtooling illustrated in FIGS. 10-22.

It should be noted that the same fixture 44 that is used to form thearray 10 of FIGS. 1-9 can be used to form the array 110 of FIGS. 10-22.

Now referring specifically to FIGS. 10-11, after the substrate insert 16has been placed within the insert cavity 52 and the fiber pigtails 12have been placed within the channels 26, the first clamp 56 and theguide clamp 60 are mounted to the base 42 to keep the fibers 12 withinthe channels 26.

As shown, when the fibers 12 are positioned within the channels 26, thefibers 12 define fiber pairs 112. In the depicted example, there are sixfiber pairs 112 since there are twelve total fibers 12 within thechannels 26. As shown specifically in FIG. 11, for forming crossed-overfibers, the fibers 12 defining each given pair 112 are crossed-over. Across-over point 114 is defined for each pair 112.

Now referring to FIGS. 12-15, the second clamp 58 that is used to keepthe fibers 12 against the bearing surface 50 of the base 42 is used tomove the cross-over point 114 toward the front end 46 of the base 42.For performing this step, the second clamp 58 defines pockets 68 forreceiving a plurality of vertical pins 70. Each pin 70 is located on thesecond clamp 58 such that it is positioned between a given pair 112 offibers 12 and is configured to contact both of the fibers 12 at theircross-over point 114 and move the cross-over point 114 toward the frontend 46 of the base 42, toward the channels 26.

As shown in FIGS. 12-15, the second clamp 58 is slidably moved towardthe guide clamp 60, moving each cross-over point 114 therewith.

As shown in FIG. 16, once the second clamp 58 has been moved to itsfinal position, the vertical pins 70 are removed from the second clamp58.

As shown in FIG. 17, similar to the method illustrated in FIGS. 1-9,next, the contact blades 54 are slidably moved along a directiontransverse to the longitudinal axes of the fibers 12 that are positionedwithin the channels 26 to consolidate the fibers 12. Thus, similar tothe method discussed previously, the fibers 12 are moved from aspaced-apart arrangement to a consolidated arrangement wherein thefibers 12 end up layered next to each other, ready for a ribbonizingprocess. The consolidation point 28 is illustrated in FIG. 18. When thefibers 12 have been consolidated, the fiber clamp 30 is applied at theconsolidation point 28 as shown in FIG. 19.

Referring to FIGS. 20 and 21, once the fibers 12 have been consolidatedand clamped to the substrate 16, the contact blades 54 are slidablymoved away from each other and the first and the second pieces ofadhesive tape 36, 38 are applied at the first and second spaces 62, 66,respectively, to further secure the fibers 12 to the substrate 16. FIG.22 illustrates removal of the guide clamp 60 after the pieces ofadhesive tape 36, 38 have been applied.

As discussed previously, FIG. 23 illustrates the inventive fiber opticarray 110 formed according to the method and tooling illustrated inFIGS. 10-22.

It should be noted that a different clip 132 may be used for clampingcrossed-over fiber pairs 112 versus horizontally flat fibers 12. Forexample, the clip 132 may define a clamping surface that has aconfiguration that accommodates and mates with the shape of thecrossed-over fiber pairs 112 (such as having a curved recessed area)versus a flat clamping surface used to clamp horizontally layered flatfibers 12 such as shown in FIG. 1.

Also, in some embodiments, a single clip 132 may be used for bothcrossed-over fiber pairs 112 and horizontally layered fibers 12. Asnoted above, such a single clip 132 may include an adhesive foam pad 33underside of the clip. Even though the clip 132 may have been moldedwith a recessed area thereunder for mating with the shape of thecrossed-over fiber pairs 112, with the use of an adhesive foam pad 33(shown in FIG. 9A), the clip 132 can still provide a flat surface torestrain horizontally layered fibers 12. If the clip 132 is used withcrossed-over fiber pairs 112, the foam pad 33 can be further pressed toconform to the recessed configuration at the underside of the clip 132to restrain the crossed-over fiber pairs 112.

Now referring to FIGS. 24-31, an example method and tooling for forminga fiber optic array 210 similar to that shown in FIGS. 1 and 23 isillustrated. However, the array 210 formed by the method illustrated inFIGS. 24-31 is an example of an array that can form a part of a flexibleoptical circuit 200 as discussed above. The array 210 formed by themethod illustrated in FIGS. 24-31 is provided as a preform that can befurther processed into a flexible optical circuit 200 by, for example,securing the formed array 210 between two polymeric sheets. FIG. 32shows an example of a flexible optical circuit 200 formed from the array210 manufactured by the inventive method and tooling illustrated inFIGS. 24-31.

Now referring to FIG. 24, the fixture 244 for forming the array 210 isshown. Similar to fixture 44, the fixture 244 defines a base 242 havinga front end 246, a rear end 248, and a bearing surface 250 extendingtherebetween against which the fibers 12 can be laid. Unlike the base 42shown in FIGS. 1-23, the base 242 defines channels 226 adjacent thefront end 246 that are formed integrally therewith.

The channels 226 define curved portions 240 at rear ends thereof fortransitioning the fibers 12 from the channels 226, wherein the fibers 12are at a spaced-apart arrangement, to a consolation point 228 on thebase 242, wherein the fibers 12 are provided in a consolidatedarrangement with the fibers 12 layered next to each other for furtherribbonizing. FIG. 24A is a close-up view illustrating the curvedportions 240 of the channels 226.

Now referring to FIGS. 25-26, once the fibers 12 are laid within thechannels 226 of the base 242, a first clamp 256 is mounted adjacent thefront end 246 of the base 242 for keeping the fibers 12 within thechannels 226. A weight 257 may also be used to clamp the fibers 12 inplace temporarily. A second clamp 258 is applied adjacent the rear end248 of the base 242 for keeping the fibers 12 against the bearingsurface 250 thereof, and a temporary cover 260 is placed between thefirst and second clamps 256, 258.

As shown in FIGS. 27-28, once contact blades 254 of the fixture 244 areslidably moved to consolidate the fibers 12, the temporary cover 260 maybe removed. Similar to the functionality of the guide clamp 60 used inthe method of FIGS. 1-23, the temporary cover 260 defines a space 262for positioning a first piece of adhesive tape 236 on the fibers 12. Thespace 262 is illustrated in a close-up view in FIG. 28A.

As shown in FIG. 29, the first piece of adhesive tape 236 is applied onthe fibers 12 at the space 262, and a second piece of tape 238 isapplied at the consolidated portion 229. Unlike the arrays 10/110illustrated in FIGS. 1-23, the first and second pieces of tape 236, 238are applied only to the fibers 12 (not to a separate substrate structure16) and are primarily used to keep the fibers 12 in the arrangementformed by the fixture 244.

Next, as shown in FIGS. 30-31, the second clamp 258 is removed from thebase 242 and the contact blades 254 are slidably moved apart. The fiberoptic array 210 may be removed from the fixture 244 by peeling thepieces of tape 236, 238 from the fixture 244 and pulling on theconsolidated portion 229 of the array 210 in a rearward direction. Asthe array 210 is pulled, the next array 210 is started (as shown in FIG.24). The fibers 12 that extend forwardly from the first piece ofadhesive tape 236 are cut at the desired length and are ready for atermination process as discussed above. Various surfaces of the fixture244, such as the bearing surface 250 and surfaces of the blades 254, maybe Teflon® coated to facilitate peeling of the pieces of tape 236, 238.

FIG. 32 illustrates an example of a flexible optical circuit 200 formedfrom the array 210 manufactured by the inventive method and toolingillustrated in FIGS. 24-31. As noted above, the array 210 formed by thetooling and method of FIGS. 24-31 may serve as a preform that can befurther processed into the flexible optical circuit 200 shown in FIG.32. The first and second pieces of tape 236, 238 may be used totemporarily hold the fibers 12 at the desired orientation before thefibers 12 are secured between two polymeric flexible sheets to form theflexible optical circuit 200. The pieces of tape 236, 238 may be trimmedto the required profile before or after the placement of the fibers 12within the flexible polymeric substrates/sheets that form the flexibleoptical circuit 200. It should be noted that in other embodiments, thefirst and second pieces of adhesive tape 236, 238 may themselves defineor be part of the polymeric substrates used to form the flexible opticalcircuit 200.

If crossing-over of the fibers 12 is required for the circuitry of thearray to be formed, a second clamp similar to the second clamp 58 shownin FIGS. 12-17 using vertical pins 70 may be utilized.

Having described the preferred aspects and embodiments of the presentdisclosure, modifications and equivalents of the disclosed concepts mayreadily occur to one skilled in the art. However, it is intended thatsuch modifications and equivalents be included within the scope of theclaims which are appended hereto.

PARTS LIST

-   10 fiber optic array-   12 fiber-   14 termination-   16 substrate/insert-   18 ferrule-   20 ferrule hub-   22 front end of substrate-   24 rear end of substrate-   26 channel-   28 fiber consolidation point-   30 fiber clamp-   32 clip-   33 foam pad-   34 opening-   36 first piece of adhesive tape-   38 second piece of adhesive tape-   40 curved portion of channel-   42 base-   44 fixture-   46 front end of base-   48 rear end of base-   50 bearing surface-   52 insert cavity-   54 contact blades-   56 first clamp-   58 second clamp-   60 guide clamp-   62 first space-   64 opening-   66 second space-   68 pocket-   70 vertical pin-   110 fiber optic array-   112 fiber pair-   114 cross-over point-   132 clip-   200 flexible optical circuit-   210 fiber optic array-   226 channel-   228 consolidation point-   229 consolidated portion of array-   236 first piece of adhesive tape-   238 second piece of adhesive tape-   240 curved portion of channel-   242 base-   244 fixture-   246 front end of base-   248 rear end of base-   250 bearing surface-   254 contact blades-   256 first clamp-   257 weight-   258 second clamp-   260 temporary cover-   262 space

What is claimed is:
 1. A fiber optic array, comprising: a plurality ofoptical fibers, each optical fiber including a buffer tube portionsurrounding the optical fiber; a substrate for supporting the pluralityof optical fibers, the substrate defining a first end and a second endand a first outer edge and a second outer edge perpendicular to thefirst and second ends; and a plurality of spaced-apart channels definedby the substrate, the channels defining parallel portions at the firstend of the substrate, the spaced-apart channels provided in a stackedarrangement extending from the first outer edge to the second outeredge, wherein the spaced-apart channels define open top ends forreceiving the optical fibers therein such that the parallel portions ofthe channels defined at the first end of the substrate are sized tofrictionally receive and secure the buffer tube portions of the opticalfibers without an additional structure covering top sides of the opticalfibers; wherein the plurality of optical fibers are positioned on thesubstrate such that the optical fibers extend from being spaced-apartvia the channels to a consolidated arrangement wherein the fibers arelayered next to each other, and wherein the plurality of optical fibersare positioned within the spaced-apart channels such that a majority ofeach optical fiber is uncovered along a length thereof as the opticalfibers extend from the first end to the second end of the substrate. 2.A fiber optic array according to claim 1, wherein the substrate is aninsert configured to be removably placed within a fiber optic cassette.3. A fiber optic array according to claim 1, wherein the substrate is aone-piece substrate.
 4. A fiber optic array according to claim 3,wherein the plurality of spaced-apart channels are formed integrallywith the one-piece substrate as a unitary structure.
 5. A fiber opticarray according to claim 1, wherein the parallel portions of thespaced-apart channels at the first end of the substrate are straightparallel portions, wherein the spaced-apart channels also define curvedrear portions for transitioning the optical fibers from the straightparallel portions inwardly away from the first and second outer edgestoward a central portion of the substrate with minimum bend radiusprotection.
 6. A fiber optic array according to claim 1, wherein thesubstrate is configured such that the optical fibers at the channelsextend outwardly from the channels to an exterior of the substrate toform pigtails that are terminated with fiber optic ferrules, wherein thesubstrate is configured to position the optical fibers therein such thatthe entirety of each of the fiber optic ferrules extends out past thefirst end of the substrate.
 7. A fiber optic array according to claim 1,further comprising a fiber clamp provided at the second end of thesubstrate, the fiber clamp securing the consolidated fibers at thesecond end of the substrate, wherein the fiber clamp is defined by aclip that is snap-fit interlocked to the substrate.
 8. A fiber opticarray according to claim 1, wherein the optical fibers supported by thesubstrate are further secured to the substrate via at least one piece ofadhesive tape.
 9. A method for forming a fiber optic array that definesa plurality of discrete fibers extending from a spaced-apart arrangementto a consolidated arrangement wherein the fibers are layered next toeach other, the method comprising: laying the fibers within spaced-apartchannels defined by a substrate that is provided as a removable insertof a fixture, the channels having parallel portions; abutting and movingthe fibers in a direction transverse to longitudinal axes of the fibersto consolidate the fibers; securing together the fibers at both thespaced-apart portion of the array and the consolidated portion of thearray; and removing the substrate from the fixture after thespaced-apart portion and the consolidated portion of the fibers havebeen secured to the substrate.
 10. A method according to claim 9,wherein the fibers are placed within the channels such that portionsthereof extend outwardly from the channels to form pigtails, wherein thepigtails are terminated with fiber optic ferrules.
 11. A methodaccording to claim 9, wherein the plurality of discrete fibers definepairs of fibers, the method further comprising crossing over the fibersof each of the pairs to form crossed-over fibers before consolidatingthe fibers.
 12. A method according to claim 11, further comprisingcontacting both fibers of a given pair at a cross-over point by avertical pin to move the cross-over point toward the channels defined onthe fixture.
 13. A fixture for forming a fiber optic array that definesa plurality of discrete fibers extending from a spaced-apart arrangementto a consolidated arrangement, wherein the fibers are layered next toeach other for a further securing process that keeps the fiberstogether, the fixture comprising: at least one contact blade that isconfigured to move on the fixture along a direction transverse tolongitudinal axes of the plurality of discrete fibers for consolidatingthe fibers, the fixture further defining channels at a front end thereoffor supporting the fibers in the spaced-apart arrangement, wherein thefixture includes a first clamp adjacent the front end of the fixture forkeeping the fibers within the channels in the spaced-apart arrangementand a second clamp adjacent a rear end of the fixture for keeping thefibers against a bearing surface of the fixture for contact by thetransversely moving contact blade.
 14. A fixture according to claim 13,wherein the second clamp is slidable in a direction from the rear end ofthe fixture toward the front end of the fixture.
 15. A fixture accordingto claim 13, wherein the channels define curved rear portions fortransitioning the plurality of discrete fibers from the spaced-apartarrangement toward a consolidation point at which the fibers are to belayered next to each other for further securing to keep the fiberstogether.
 16. A fixture according to claim 13, wherein the channels aredefined by a removable substrate that forms a part of the fiber opticarray manufactured using the fixture.
 17. A fixture according to claim14, wherein the second clamp defines a plurality of vertical pins, eachpin positioned to be in between a given pair of fibers such that if thefibers of the given pair are crossed-over, the pin can contact bothfibers of the given pair at a cross-over point and move the cross-overpoint toward the front end of the fixture.